Professional Documents
Culture Documents
fm 1 ページ 2012年12月10日 月曜日 午前10時6分
Engine CONTENTS
Workshop Title Section
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materials carefully.
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WARNING(US).fm 1 ページ 2010年3月11日 木曜日 午後1時28分
WARNING
Servicing a vehicle can be dangerous. If you have not received
service-related training, the risks of injury, property damage, and
failure of servicing increase. The recommended servicing procedures
for the vehicle in this workshop manual were developed with
Mazda-trained technicians in mind. This manual may be useful to
non-Mazda trained technicians, but a technician with our
service-related training and experience will be at less risk when
performing service operations. However, all users of this manual are
expected to at least know general safety procedures.
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the hazardous consequences that might result from failure to follow
the procedures.
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Number Of Digits For Reassembly . . . . . . . . . . . . . . . . . . . . . 00-00–7
Converted Values . . . . . . . . . . . . . . . . 00-00–5 Adjustment . . . . . . . . . . . . . . . . . . . . . . 00-00–8
Converted Value Rounding Off And Rubber Parts and Tubing . . . . . . . . . . . 00-00–8
Rounding Up/down . . . . . . . . . . . . . . . 00-00–5 Torque Formulas . . . . . . . . . . . . . . . . . 00-00–8
ABBREVIATIONS. . . . . . . . . . . . . . . . . . . 00-00–6 Vise . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-00–9
FUNDAMENTAL PROCEDURES. . . . . . . 00-00–6
End of Toc
HOW TO USE THIS MANUAL
WM: GENERAL INFORMATION
id000000000100
Range of Topics
• This manual contains procedures for performing all required service operations. The procedures are divided
into the following basic operations:
— Removal/Installation
— Disassembly/Assembly
— Replacement
— Inspection
— Adjustment
• Simple operations which can be performed easily just by looking at the actual unit (i.e., removal/installation of
parts, cleaning of parts, and visual inspection) have been omitted.
00-00–1
1A36-1U-12L.book 2 ページ 2012年12月10日 月曜日 午前9時25分
GENERAL INFORMATION
Service Procedure
Inspection, adjustment
• Inspection and adjustment procedures are
divided into steps. Important points regarding the SHOWS PROCEDURE ORDER
location and contents of the procedures are FOR SERVICE
explained in detail and shown in the illustrations.
Fluid Pressure Inspection
1. Assemble the SSTs as shown in the figure.
Tightening torque
39—49 N·m {4.0—5.0 kgf·m, 29—36 ft·lbf}
49 1232 670A
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Repair procedure
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1. Most repair operations begin with an overview illustration. It identifies the components, shows how the parts fit
together, and describes visual part inspection. However, only removal/installation procedures that need to be
performed methodically have written instructions.
2. Expendable parts, tightening torques, and symbols for oil, grease, and sealant are shown in the overview
illustration. In addition, symbols indicating parts requiring the use of special service tools or equivalent are also
shown.
3. Procedure steps are numbered and the part that is the main point of that procedure is shown in the illustration
with the corresponding number. Occasionally, there are important points or additional information concerning a
procedure. Refer to this information when servicing the related part.
00-00–2
1A36-1U-12L.book 3 ページ 2012年12月10日 月曜日 午前9時25分
GENERAL INFORMATION
SHOWS SERVICE
Procedure ITEM (S)
INDICATES ANY RELEVANT
1
LOWER TRAILING LINK, UPPER TRAILING LINK REMOVAL/INSTALLATION REFERENCES WHICH NEED
1. Jack up the rear of the vehicle and support it with safety stands. TO BE FOLLOWED DURING
"Removal/Installation" 2. Remove the undercover. (See 01-10-4 Undercover Removal) 00-00
Portion 3. Remove in the order indicated in the table. INSTALLATION
4. Install in the reverse order of removal.
2 5. Inspect the rear wheel alignment and adjust it if necessary.
"Inspection After SHOWS SPECIAL
Installation" Portion 11 SERVICE TOOL (SST)
9 SST
SHOWS PROCEDURE ORDER FOR SERVICE OPERATION
GREASE
FOR SERVICE 12 SST R
SHOWS TIGHTENING
TORQUE
SPECIFICATIONS SHOWS NON-REUSEABLE PARTS
SST
3
5
6 SHOWS DETAILS
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SST
GREASE
4 R
94—116 {9.5—11.9, 69—86}
2 118—156 {12.0—16.0, 87—115} SHOWS TIGHTENING
SHOWS THERE 1 R TORQUE UNITS
ARE REFERRAL
N·m {kgf·m, ft·lbf}
NOTES FOR SERVICE
1 Split pin 7 Split pin
2 Nut 8 Nut
3 Lower trailing link ball joint 9 Upper trailing link ball joint
(See 02-14-5 Lower Trailing Link Ball Joint Removal Note) (See 02-14-5 Upper Trailing Link Ball Joint Removal Note)
4 Bolt 10 Nut
5 Lower trailing link 11 Upper trailing link
6 Dust boot (lower trailing link) 12 Dust boot (upper trailing link)
Lower Trailing Link Ball Joint, Upper Trailing Link 49 T028 304 UPPER TRAILING LINK
Ball Joint Removal Note 49 T028 305 LOWER TRAILING LINK
Remove the ball joint using the SSTs.
SHOWS SPECIAL
SERVICE TOOL (SST)
NO. KNUCKLE
49 T028 303
SHOWS REFERRAL
NOTES FOR
SERVICE
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00-00–3
1A36-1U-12L.book 4 ページ 2012年12月10日 月曜日 午前9時25分
GENERAL INFORMATION
Symbols
• There are eight symbols indicating oil, grease, fluids, sealant, and the use of SST or equivalent. These symbols
show application points or use of these materials during service.
Symbol Meaning Kind
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Appropriate
SEALANT Apply sealant
sealant
Appropriate
P Apply petroleum jelly
petroleum jelly
Use SST or
SST Appropriate tools
equivalent
Advisory Messages
• You will find several Warnings, Cautions, Notes, Specifications and Upper and Lower Limits in this
manual.
Warning
• A Warning indicates a situation in which serious injury or death could result if the warning is ignored.
Caution
• A Caution indicates a situation in which damage to the vehicle or parts could result if the caution is ignored.
Note
• A Note provides added information that will help you to complete a particular procedure.
Specification
• The values indicate the allowable range when performing inspections or adjustments.
00-00–4
1A36-1U-12L.book 5 ページ 2012年12月10日 月曜日 午前9時25分
GENERAL INFORMATION
UNITS
id000000100400
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L (liter)
US qt (U.S. quart)
Imp qt (Imperial quart)
Volume ml (milliliter)
cc (cubic centimeter)
cu in (cubic inch)
fl oz (fluid ounce)
g (gram)
Weight
oz (ounce)
00-00–5
1A36-1U-12L.book 6 ページ 2012年12月10日 月曜日 午前9時25分
GENERAL INFORMATION
ABBREVIATIONS
id000000010100
End Of Sie
FUNDAMENTAL PROCEDURES
GAIHAN: -
id000000750100
Preparation of Tools and Measuring Equipment
• Be sure that all necessary tools and measuring
equipment are available before starting any work.
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Disassembly
• If the disassembly procedure is complex,
requiring many parts to be disassembled, all parts
should be marked in a place that will not affect
their performance or external appearance and
identified so that reassembly can be performed
easily and efficiently.
bpe2ue00000112
00-00–6
1A36-1U-12L.book 7 ページ 2012年12月10日 月曜日 午前9時25分
GENERAL INFORMATION
Inspection During Removal, Disassembly
• When removed, each part should be carefully
inspected for malfunction, deformation, damage
and other problems.
00-00
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Arrangement of Parts
• All disassembled parts should be carefully
arranged for reassembly.
• Be sure to separate or otherwise identify the parts
to be replaced from those that will be reused.
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Cleaning of Parts
• All parts to be reused should be carefully and
thoroughly cleaned in the appropriate method.
Warning
• Using compressed air can cause dirt and
other particles to fly out causing injury to
the eyes. Wear protective eye wear
whenever using compressed air.
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Reassembly
• Standard values, such as torques and certain
adjustments, must be strictly observed in the
reassembly of all parts.
• If removed, the following parts should be replaced
with new ones:
— Oil seals
— Gaskets
— O-rings
— Lockwashers
— Cotter pins
— Nylon nuts
bpe2ue00000115
00-00–7
1A36-1U-12L.book 8 ページ 2012年12月10日 月曜日 午前9時25分
• Depending on location:
— Sealant and gaskets, or both, should be
applied to specified locations. When sealant
is applied, parts should be installed before
sealant hardens to prevent leakage.
— Oil should be applied to the moving
components of parts.
— Specified oil or grease should be applied at
the prescribed locations (such as oil seals)
before reassembly.
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Adjustment
• Use suitable gauges and testers when making
adjustments.
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Torque Formulas
• When using a torque wrench-SST or equivalent
combination, the written torque must be SST
3
GENERAL INFORMATION
Vise
• When using a vise, put protective plates in the
jaws of the vise to prevent damage to parts.
End Of Sie
00-00
PROTECTIVE PLATES
bpe2ue00000120
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00-00–9
1A36-1U-12L.book 10 ページ 2012年12月10日 月曜日 午前9時25分
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1A36-1U-12L.book 1 ページ 2012年12月10日 月曜日 午前9時25分
ENGINE 01SECTION
01-10
Toc of SCT
MECHANICAL. . . . . . . . . . . . . . 01-10 SERVICE TOOLS . . . . . . . . . . . 01-60
TECHNICAL DATA . . . . . . . . . . 01-50
Toc of SCT
01-10 MECHANICAL
ELECTRIC VARIABLE VALVE TIMING Rear Oil Seal Disassembly Note . . . . . 01-10–21
MOTOR/DRIVER INSPECTION . . . . . . . 01-10–2 CYLINDER BLOCK
HYDRAULIC VARIABLE VALVE TIMING DISASSEMBLY (II) . . . . . . . . . . . . . . . . 01-10–22
ACTUATOR INSPECTION . . . . . . . . . . . 01-10–3 Pilot Bearing Disassembly Note . . . . . . 01-10–23
ELECTRIC VARIABLE VALVE TIMING Connecting Rod Cap
ACTUATOR INSPECTION . . . . . . . . . . . 01-10–3 Disassembly Note . . . . . . . . . . . . . . . 01-10–23
OIL CONTROL VALVE (OCV) Connecting Rod Bearing
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INSPECTION . . . . . . . . . . . . . . . . . . . . . 01-10–4 Disassembly Note . . . . . . . . . . . . . . . 01-10–23
Coil Resistance Inspection . . . . . . . . . . 01-10–4 Piston, Connecting Rod
Spool Valve Operation Inspection . . . . . 01-10–4 Disassembly Note . . . . . . . . . . . . . . . 01-10–23
HYDRAULIC LASH ADJUSTER (HLA) Snap Ring Disassembly Note. . . . . . . . 01-10–24
INSPECTION . . . . . . . . . . . . . . . . . . . . . 01-10–5 Lower Cylinder Block
ROCKER ARM INSPECTION. . . . . . . . . . 01-10–5 Disassembly Note . . . . . . . . . . . . . . . 01-10–24
ENGINE OVERHAUL SERVICE Thrust Bearing And Main Bearing
WARNING. . . . . . . . . . . . . . . . . . . . . . . . 01-10–5 Disassembly Note . . . . . . . . . . . . . . . 01-10–25
ENGINE MOUNTING/DISMOUNTING . . . 01-10–6 Crankshaft Disassembly Note . . . . . . . 01-10–25
Mounting . . . . . . . . . . . . . . . . . . . . . . . . 01-10–6 CYLINDER HEAD INSPECTION. . . . . . . 01-10–25
Dismounting . . . . . . . . . . . . . . . . . . . . . 01-10–6 VALVE SEAT INSPECTION/REPAIR. . . . 01-10–26
TIMING CHAIN DISASSEMBLY. . . . . . . . 01-10–7 VALVE, VALVE GUIDE
Water Pump Pulley INSPECTION . . . . . . . . . . . . . . . . . . . . . 01-10–27
Disassembly Note . . . . . . . . . . . . . . . . 01-10–9 VALVE GUIDE REPLACEMENT . . . . . . . 01-10–29
Crankshaft Pulley Lock Bolt Removal . . . . . . . . . . . . . . . . . . . . . . . . 01-10–29
Disassembly Note . . . . . . . . . . . . . . . . 01-10–10 Installation . . . . . . . . . . . . . . . . . . . . . . 01-10–29
Oil Pan Disassembly Note. . . . . . . . . . . 01-10–10 VALVE SPRING INSPECTION . . . . . . . . 01-10–29
Engine Front Cover CAMSHAFT INSPECTION . . . . . . . . . . . 01-10–30
Disassembly Note . . . . . . . . . . . . . . . . 01-10–10 CYLINDER BLOCK INSPECTION . . . . . 01-10–32
Front Oil Seal Disassembly Note . . . . . 01-10–11 OIL JET VALVE INSPECTION . . . . . . . . 01-10–32
Chain Tensioner Disassembly Note . . . 01-10–11 PISTON INSPECTION . . . . . . . . . . . . . . . 01-10–32
Oil Pump Chain Disassembly Note . . . . 01-10–12 PISTON RING INSPECTION . . . . . . . . . . 01-10–33
CYLINDER HEAD DISASSEMBLY (I) . . . 01-10–14 PISTON PIN INSPECTION . . . . . . . . . . . 01-10–34
Electric Variable Valve Timing Actuator, PISTON AND CONNECTING ROD
Hydraulic Variable Valve Timing INSPECTION . . . . . . . . . . . . . . . . . . . . . 01-10–35
Actuator Disassembly Note. . . . . . . . . 01-10–16 CONNECTING ROD INSPECTION . . . . . 01-10–35
Camshaft Cap Disassembly Note . . . . . 01-10–16 CONNECTING ROD CLEARANCE
Rocker Arm Disassembly Note . . . . . . . 01-10–16 INSPECTION . . . . . . . . . . . . . . . . . . . . . 01-10–35
HLA Disassembly Note . . . . . . . . . . . . . 01-10–16 CRANKSHAFT INSPECTION . . . . . . . . . 01-10–36
Cylinder Head Disassembly Note . . . . . 01-10–16 DUAL-MASS FLYWHEEL
CYLINDER HEAD INSPECTION . . . . . . . . . . . . . . . . . . . . . 01-10–37
DISASSEMBLY (II) . . . . . . . . . . . . . . . . . 01-10–17 Inspection Before Removal . . . . . . . . . 01-10–37
Valve Keeper Disassembly Note . . . . . . 01-10–18 Inspection After Removal . . . . . . . . . . . 01-10–38
Valve Seal Disassembly Note . . . . . . . . 01-10–18 PILOT BEARING INSPECTION . . . . . . . 01-10–39
CYLINDER BLOCK BOLT INSPECTION . . . . . . . . . . . . . . . . . 01-10–39
DISASSEMBLY (I) . . . . . . . . . . . . . . . . . 01-10–19 CYLINDER BLOCK ASSEMBLY (I) . . . . 01-10–40
Dual-mass Flywheel (MTX)/ Drive Thrust Bearing And Main Bearing
Plate (ATX) Installation Bolt Assembly Note . . . . . . . . . . . . . . . . . . 01-10–41
Disassembly Note . . . . . . . . . . . . . . . . 01-10–20 Plate Assembly Note . . . . . . . . . . . . . . 01-10–42
Dual-mass Flywheel Lower Cylinder Block
Disassembly Note (MTX) . . . . . . . . . . 01-10–21 Assembly Note . . . . . . . . . . . . . . . . . . 01-10–42
01-10–1
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MECHANICAL
Piston Pin Assembly Note. . . . . . . . . . . 01-10–44 Thermostat Assembly Note . . . . . . . . . 01-10–58
Snap Ring Assembly Note . . . . . . . . . . 01-10–44 CYLINDER HEAD ASSEMBLY (II) . . . . . 01-10–59
Piston Ring Assembly Note. . . . . . . . . . 01-10–45 Cylinder Head Assembly Note . . . . . . . 01-10–61
Connecting Rod Bearing Water Inlet Pipe Assembly Note. . . . . . 01-10–62
Assembly Note . . . . . . . . . . . . . . . . . . 01-10–46 HLA Assembly Note . . . . . . . . . . . . . . . 01-10–63
Piston, Connecting Rod Rocker Arm Assembly Note . . . . . . . . . 01-10–63
Assembly Note . . . . . . . . . . . . . . . . . . 01-10–46 Camshaft Assembly Note. . . . . . . . . . . 01-10–64
Connecting Rod Cap Electric Variable Valve Timing Actuator,
Assembly Note . . . . . . . . . . . . . . . . . . 01-10–47 Hydraulic Variable Valve Timing
Pilot Bearing Assembly Note . . . . . . . . 01-10–47 Actuator Assembly Note. . . . . . . . . . . 01-10–66
CYLINDER BLOCK ASSEMBLY (II) . . . . 01-10–48 TIMING CHAIN ASSEMBLY . . . . . . . . . . 01-10–67
Balancer Unit Assembly Note . . . . . . . . 01-10–49 Oil Pump Chain Assembly Note . . . . . . 01-10–69
Oil Pump Assembly Note . . . . . . . . . . . 01-10–50 Timing Chain Assembly Note . . . . . . . . 01-10–71
Water Pump Assembly Note . . . . . . . . . 01-10–51 Engine Front Cover Assembly Note . . . 01-10–74
Rear Oil Seal Assembly Note . . . . . . . . 01-10–52 Oil Pan Assembly Note . . . . . . . . . . . . 01-10–77
End Plate Assembly Note . . . . . . . . . . . 01-10–53 Electric Variable Valve Timing Motor/
Dual-mass Flywheel (MTX)/ Drive Driver Assembly Note. . . . . . . . . . . . . 01-10–79
Plate (ATX) Installation Bolt Front Oil Seal Assembly Note . . . . . . . 01-10–80
Assembly Note . . . . . . . . . . . . . . . . . . 01-10–53 Crankshaft Pulley Lock Bolt
Knock Sensor (KS) Assembly Note . . . 01-10–54 Assembly Note . . . . . . . . . . . . . . . . . . 01-10–80
CYLINDER HEAD ASSEMBLY (I) . . . . . . 01-10–55 Water Pump Pulley Assembly Note . . . 01-10–81
Valve Seal Assembly Note . . . . . . . . . . 01-10–56 Oil Shower Pipe Assembly Note . . . . . 01-10–81
Valve Spring Assembly Note. . . . . . . . . 01-10–56 Cylinder Head Cover
Valve Keeper Assembly Note . . . . . . . . 01-10–57 Assembly Note . . . . . . . . . . . . . . . . . . 01-10–82
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Water Outlet Assembly Note . . . . . . . . . 01-10–57
End of Toc
ELECTRIC VARIABLE VALVE TIMING MOTOR/DRIVER INSPECTION
WM: -
id011000828100
Caution
• Do not disassemble the electric variable valve timing motor/driver because it is a precision unit.
• Do not apply excessive force when rotating the electric variable valve timing motor joint. If it is
rotated with excessive force, the electric variable valve timing motor could be damaged.
1. Rotate the electric variable valve timing motor joint to the left and right by your fingers and verify that it rotates
smoothly in 15° increments.
Note
• Rotate the joint area smoothly using only the tips of your fingers.
• The electric variable valve timing motor joint moves in 15° increments, and if the joint is moved 24 times, it
rotates one full rotation.
JOINT
01-10–2
1A36-1U-12L.book 3 ページ 2012年12月10日 月曜日 午前9時25分
MECHANICAL
HYDRAULIC VARIABLE VALVE TIMING ACTUATOR INSPECTION
id011000126800
Caution
• Do not disassemble the hydraulic variable valve timing actuator because it is a precision unit.
Caution
• Do not disassemble the electric variable valve timing actuator because it is a precision unit.
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1. Rotate the eccentric shaft of the electric variable
valve timing actuator to the left and right by hand
and verify that it rotates smoothly. JOINT GROOVE
• If it does not rotate smoothly, replace the
electric variable valve timing actuator.
End Of Sie
WM: OIL CONTROL VALVE (OCV)
01-10–3
1A36-1U-12L.book 4 ページ 2012年12月10日 月曜日 午前9時25分
MECHANICAL
OIL CONTROL VALVE (OCV) INSPECTION
id011000801400
Coil Resistance Inspection
1. Measure the resistance between terminals A and
B using an ohmmeter. OIL CONTROL VALVE (OCV)
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Note
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• When applying battery positive voltage
between the OCV terminals, the connection
can be either of the following: SPOOL VALVE
— Positive battery cable to terminal A, (MAXIMUM VALVE TIMING
negative battery cable to terminal B ADVANCE POSITION)
— Positive battery cable to terminal B,
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negative battery cable to terminal A
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SPOOL VALVE
(MAXIMUM VALVE TIMING
RETARD POSITION)
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01-10–4
1A36-1U-12L.book 5 ページ 2012年12月10日 月曜日 午前9時25分
MECHANICAL
HYDRAULIC LASH ADJUSTER (HLA) INSPECTION
id011000805000
1. Visually inspect the HLA surface where it contacts
the rocker arm for wear or damage. ROCKER ARM
• If there is any malfunction, replace the HLA. CONTACT SURFACE
End Of Sie
WM: ROCKER ARM
01-10
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arm.
End Of Sie
EN: ENGINE COMPLETE
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Warning
• Continuous exposure to USED engine oil has been shown to cause skin cancer in laboratory mice.
Protect your skin by washing with soap and water immediately after performing work.
End Of Sie
01-10–5
1A36-1U-12L.book 6 ページ 2012年12月10日 月曜日 午前9時25分
MECHANICAL
ENGINE MOUNTING/DISMOUNTING
id011000507000
Mounting
1. Install the SST (arms) to the three positions as shown in the figure and temporarily tighten the bolts (Part No.
9YA20-1003 or M10 × 1.5 length 90 mm {3.55 in}).
SST INSTALLATION HOLE SST INSTALLED
49 L010 102
ENGINE FRONT
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positions of the SST (plate) as shown in the
figure. 49 L010 101
49 L010 104
49 L010 105
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Tightening torque
30—41 N·m {3.1—4.1 kgf·m, 23—30 ft·lbf}
Dismounting
1. Dismount in the reverse order of mounting.
End Of Sie
01-10–6
1A36-1U-12L.book 7 ページ 2012年12月10日 月曜日 午前9時25分
MECHANICAL
TIMING CHAIN DISASSEMBLY
id011000505500
Caution
• If the camshaft is rotated with the timing chain removed and the piston at the top dead center
position, the valve may contact the piston and the engine could be damaged. When rotating the
camshaft with the timing chain removed, rotate it after lowering the piston from the top dead
center position.
• When rotating the camshaft using a 01-10
WRENCH
wrench on the cast hexagon, the wrench CAMSHAFT
may contact the rocker arm and damage CAST HEXAGON
the rocker arm. To prevent damage to the
rocker arm when holding the camshaft on
the cast hexagon, use a wrench on the
rear side of the engine as shown in the
figure to secure a clearance between the
cam.
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DOES NOT CONTACT
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Note
• Width at the cast hexagon of the camshaft is CAMSHAFT
22—24 mm {0.87—0.94 in}.
CAST HEXAGON
22—24 mm
{0.87—0.94 in}
am3uuw00009029
01-10–7
1A36-1U-12L.book 8 ページ 2012年12月10日 月曜日 午前9時25分
MECHANICAL
1. Disassemble in the order indicated in the table.
2 A
1
3
10 A
R
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8
4
12
R 13
6 7 11
SST
22
15 24
23
17
14
16 18
9
21 19 20
SST SST
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01-10–8
1A36-1U-12L.book 9 ページ 2012年12月10日 月曜日 午前9時25分
MECHANICAL
6 Crankshaft pulley lock bolt 15 Timing chain
(See 01-10-10 Crankshaft Pulley Lock Bolt 16 Chain guide (No.2)
Disassembly Note.)
17 Crankshaft sprocket
7 Crankshaft pulley
18 Oil pump chain tensioner
8 Electric variable valve timing motor/driver (See 01-10-12 Oil Pump Chain Disassembly Note.)
9 Oil pan 19 Balancer shaft sprocket
(See 01-10-10 Oil Pan Disassembly Note.) (See 01-10-12 Oil Pump Chain Disassembly Note.)
10 Engine front cover 01-10
20 Oil pump chain
(See 01-10-10 Engine Front Cover Disassembly (See 01-10-12 Oil Pump Chain Disassembly Note.)
Note.)
21 Oil pump driven sprocket
11 Front oil seal (See 01-10-12 Oil Pump Chain Disassembly Note.)
(See 01-10-11 Front Oil Seal Disassembly Note.)
22 Oil pump chain guide
12 Chain guide (No.1)
23 Oil pump drive sprocket
13 Chain tensioner
(See 01-10-11 Chain Tensioner Disassembly Note.) 24 Key
14 Tensioner arm
Caution
• Be careful not to damage the belt groove and surface of the water pump pulley when using tools,
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otherwise it will cause wear, breakage, abnormal noise of the drive belt (stretch belt), damage to
the pulley, and rust.
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BOLT
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01-10–9
1A36-1U-12L.book 10 ページ 2012年12月10日 月曜日 午前9時25分
MECHANICAL
Crankshaft Pulley Lock Bolt Disassembly Note
1. Hold the crankshaft using the SST.
2. Remove the crankshaft pulley lock bolt.
49 E011 1A0
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adejjw00003946
Caution
• Do not apply excessive force to the
CLOTH CLOTH
screwdriver. Otherwise, the engine front
cover could be damaged.
• Be careful not to scratch or damage the
seal surface. Otherwise, it could cause
oil leakage.
am3uuw00008851
CLOTH
am3uuw00008852
01-10–10
1A36-1U-12L.book 11 ページ 2012年12月10日 月曜日 午前9時25分
MECHANICAL
Front Oil Seal Disassembly Note
1. Remove the oil seal using a flathead screwdriver
with the tip protected by a clean cloth.
CLOTH
01-10
FRONT OIL SEAL
bpe2ue00000100
cardiagn.com
bp31je00000104
Note
• When moving the exhaust camshaft back
and forth, the timing chain pushes the
plunger in the chain tensioner making it LINK PLATE
easier to operate the link plate.
PLUNGER
am3uuw00008854
am3uuw00008855
01-10–11
1A36-1U-12L.book 12 ページ 2012年12月10日 月曜日 午前9時25分
MECHANICAL
5. Insert a wire with an approx. diameter of 1.5 mm
{0.059 in} or a paper clip where the link plate hole
and the tensioner body hole overlap to secure the
link plate and lock the plunger.
6. Remove the chain tensioner.
WIRE OR
PAPER CLIP
LINK PLATE
cardiagn.com
am3uuw00008856
Note
• At this stage, only loosen the installation
bolts, do not remove them. Remove the bolts
after removing the oil pump chain tensioner.
49 E011 1A0
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01-10–12
1A36-1U-12L.book 13 ページ 2012年12月10日 月曜日 午前9時25分
MECHANICAL
4. Move the screwdriver in the direction of the arrow and press the oil pump chain, and then press on the plunger
of the oil pump chain tensioner.
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OIL PUMP CHAIN TENSIONER OIL PUMP CHAIN TENSIONER
bpe1ze00000065
Note WIRE OR
• The wire or paper clip secures the plunger, PAPER CLIP
and the tension can be released.
01-10–13
1A36-1U-12L.book 14 ページ 2012年12月10日 月曜日 午前9時25分
MECHANICAL
CYLINDER HEAD DISASSEMBLY (I)
id011000500400
Caution
• If the camshaft is rotated with the timing chain removed and the piston at the top dead center
position, the valve may contact the piston and the engine could be damaged. When rotating the
camshaft with the timing chain removed, rotate it after lowering the piston from the top dead
center position.
• When rotating the camshaft using a
WRENCH
wrench on the cast hexagon, the wrench CAMSHAFT
may contact the rocker arm and damage CAST HEXAGON
the rocker arm. To prevent damage to the
rocker arm when holding the camshaft on
the cast hexagon, use a wrench on the
rear side of the engine as shown in the
figure to secure a clearance between the
cam.
cardiagn.com
DOES NOT CONTACT
am3uuw00008837
Note
• Width at the cast hexagon of the camshaft is CAMSHAFT
22—24 mm {0.87—0.94 in}.
CAST HEXAGON
22—24 mm
{0.87—0.94 in}
am3uuw00009029
01-10–14
1A36-1U-12L.book 15 ページ 2012年12月10日 月曜日 午前9時25分
MECHANICAL
1. Disassemble in the order indicated in the table.
3
01-10
6
1
7
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8
9
WATER
PUMP
R
WITH OIL COOLER
10
8 R
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01-10–15
1A36-1U-12L.book 16 ページ 2012年12月10日 月曜日 午前9時25分
MECHANICAL
Electric Variable Valve Timing Actuator, Hydraulic Variable Valve Timing Actuator Disassembly Note
1. Hold the camshaft using a wrench on the cast
hexagon and loosen the actuator installation bolt.
bp31je00000161
E2
E3
E4
E5
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1
I2
I3
I4
I5
2 4 5 3
am3uuw00008985
ENGINE
FRONT 8 9 5 1
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01-10–16
1A36-1U-12L.book 17 ページ 2012年12月10日 月曜日 午前9時25分
MECHANICAL
CYLINDER HEAD DISASSEMBLY (II)
id011000500500
1. Disassemble in the order indicated in the table.
SST 4 3 2 1
5
6 01-10
SST R 8
9
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7
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01-10–17
1A36-1U-12L.book 18 ページ 2012年12月10日 月曜日 午前9時25分
MECHANICAL
Valve Keeper Disassembly Note
1. Remove the valve keeper using the SSTs.
49 B012 0A2A
49 0636 100B
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bpe1ze00000014
49 S120 170
VALVE SEAL
VALVE GUIDE
bpe1ze00000015
End Of Sie
VALVE SEAL
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01-10–18
1A36-1U-12L.book 19 ページ 2012年12月10日 月曜日 午前9時25分
MECHANICAL
CYLINDER BLOCK DISASSEMBLY (I)
id011000500600
Caution
• Do not disassemble the oil pump, water pump and balancer unit because it is a precision unit.
ATX 01-10
SST
R
R
7 6 5 4 3
8 R
MTX
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5 SST
R
1 3
11
R
10
9
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01-10–19
1A36-1U-12L.book 20 ページ 2012年12月10日 月曜日 午前9時25分
MECHANICAL
Dual-mass Flywheel (MTX)/ Drive Plate (ATX) Installation Bolt Disassembly Note
Dual-mass flywheel installation bolt (MTX)
1. Hold the crankshaft using the SST (49 E011 1A0).
2. Loosen the bolts uniformly and gradually in the
order shown in the figure.
Note 8
• If the bolt installation holes are not 1
positioned properly, perform the following 6
3
procedure:
5 4
49 E011 1A0
7 2
ac5wzw00005660
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49 S120 710
am6xuw00005540
49 E011 1A0
bpe1ze00000092
01-10–20
1A36-1U-12L.book 21 ページ 2012年12月10日 月曜日 午前9時25分
MECHANICAL
Dual-mass Flywheel Disassembly Note (MTX)
Note
• When reusing the dual-mass flywheel, do not remove the SST (49 G033 102) locking the dual-mass
flywheel (secondary flywheel side) against rotation.
REAR OIL
SEAL
CLOTH
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bpe5ue00000003
01-10–21
1A36-1U-12L.book 22 ページ 2012年12月10日 月曜日 午前9時25分
MECHANICAL
CYLINDER BLOCK DISASSEMBLY (II)
id011000500700
1. Disassemble in the order indicated in the table.
6 18
9 7
R
7 17
R
8 16
15
10
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1 R
SST
5
13
3
12
2
11
14
bpe1ze00000038
01-10–22
1A36-1U-12L.book 23 ページ 2012年12月10日 月曜日 午前9時25分
MECHANICAL
13 Crankshaft 16 Thrust bearing
(See 01-10-25 Crankshaft Disassembly Note.) (See 01-10-25 Thrust Bearing And Main Bearing
14 Plate Disassembly Note.)
15 Upper main bearing 17 Oil jet valve
(See 01-10-25 Thrust Bearing And Main Bearing 18 Upper cylinder block
Disassembly Note.)
01-10
Note
• The pilot bearing does not need to be removed unless you are replacing it.
49 1285 071
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bp31je00000044
01-10–23
1A36-1U-12L.book 24 ページ 2012年12月10日 月曜日 午前9時25分
MECHANICAL
Snap Ring Disassembly Note
1. Before removing the snap ring, verify that the large end of connecting rod drops under its own weight with no
resistance. (See 01-10-35 PISTON AND CONNECTING ROD INSPECTION.)
2. Remove the snap ring using a flathead
screwdriver.
SNAP RING
bpe2ue00000022
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ENGINE
FRONT
2 6 10 7 3
B B B B B
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ENGINE
FRONT
2 6 10 7 3
A A A A A
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01-10–24
1A36-1U-12L.book 25 ページ 2012年12月10日 月曜日 午前9時25分
MECHANICAL
4. Using a screwdriver wrapped in a cloth, peel the LOWER CYLINDER BLOCK
sealant away a little at a time, and remove the
lower cylinder block.
Caution
• Do not apply excessive force to the
screwdriver. Otherwise, the lower
cylinder block could be damaged. 01-10
• Be careful not to scratch or damage the
seal surface. Otherwise, it could cause CLOTH CLOTH
oil leakage.
bpe2ue00000025
cardiagn.com
Crankshaft Disassembly Note
Caution
• Placing the crankshaft on a disassembly bench will deform or damage it because the plate for the
crankshaft position sensor signal detection installed to the crankshaft is larger than the
counterweight. Therefore, set wood blocks or similar objects on the both sides of the crankshaft
so that the plate does not contact the disassembly bench directly when placing the crankshaft on
the bench.
End Of Sie
CYLINDER HEAD INSPECTION
id011000507100
1. Inspect the cylinder head surface for cracks and other damage using a red dye penetrant.
• If there is a malfunction, replace the cylinder head.
2. Measure the combustion chamber side of the
cylinder head for distortion in six directions as
shown in the figure using a straight edge and
feeler gauge.
• If the distortion exceeds the maximum
specification, replace the cylinder head. Do
not attempt to repair the cylinder head by
milling or grinding.
01-10–25
1A36-1U-12L.book 26 ページ 2012年12月10日 月曜日 午前9時25分
MECHANICAL
3. Inspect the contact surface of the exhaust
manifold and the intake manifold for distortion by IN
measuring as shown in the figure using a straight
edge and feeler gauge.
• If the distortion on the intake manifold side
exceeds the maximum specification, replace
the cylinder head.
• If the distortion on the exhaust manifold side
exceeds the maximum specification, grind the
surface or replace the cylinder head.
EX
Maximum distortion, manifold side
IN: 0.10 mm {0.0039 in}
EX: 0.05 mm {0.002 in}
End Of Sie
VALVE SEAT INSPECTION/REPAIR
id011000501300
1. Measure the contact width of the valve face and
the valve seat using the valve lapping compound.
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• If it is not within the specification, resurface
the valve seat using the 45° valve seat cutter.
SEAT CONTACT
Standard valve seat contact width WIDTH
1.37—1.84 mm {0.0540—0.0724 in}
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COMBUSTION CHAMBER
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01-10–26
1A36-1U-12L.book 27 ページ 2012年12月10日 月曜日 午前9時25分
MECHANICAL
3. Inspect the valve seat for sinkage. Measure the
protruding length (dimension L) of the valve stem
using a valve of standard length.
• If it is not within the specification, replace the
cylinder head.
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MARGIN THICKNESS
bpe5ue00000012
01-10–27
1A36-1U-12L.book 28 ページ 2012年12月10日 月曜日 午前9時25分
MECHANICAL
4. Measure the inner diameter of each valve guide
X
using the caliper gauge. Measurement positions
total six and are in the X and Y directions, at three Y
points (A, B, and C) as shown in the figure.
• If it is not within the specification, replace the
A
valve guide.
bpe2ue00000085
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bpe2ue00000086
Maximum clearance between valve stem and
guide
0.10 mm {0.0039 in}
End Of Sie
bpe2ue00000087
01-10–28
1A36-1U-12L.book 29 ページ 2012年12月10日 月曜日 午前9時25分
MECHANICAL
VALVE GUIDE REPLACEMENT
id011000501200
Removal
1. Tap the valve guide out from combustion chamber
side using the SST.
49 B012 015
01-10
VALVE GUIDE
bpe2ue00000026
Installation
1. Apply clean engine oil to the valve guide.
2. Tap the valve guide from the camshaft side using
the SST so that the projection height (dimension
49 B012 015
A) is within the specification.
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IN: 16.4—17.0 mm {0.646—0.669 in}
EX: 16.4—17.0 mm {0.646—0.669 in}
A
End Of Sie VALVE GUIDE
CYLINDER HEAD
bpe2ue00000027
Caution
• The valve springs differ depending on the
IN and EX sides.Therefore, verify the free IN
48.96 mm {1.928 in}
length or identification paint beforehand
and inspect the valve springs.
PURPLE PAINT
EX
50.07 mm {1.971 in}
NOT PAINTED
bpe1ze00000041
01-10–29
1A36-1U-12L.book 30 ページ 2012年12月10日 月曜日 午前9時25分
MECHANICAL
1. Measure the valve spring height using the spring
tester.
• If it is not within the specification, replace the
valve spring.
bp31je00000053
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beltze00000017
End Of Sie
CAMSHAFT INSPECTION
id011000501500
1. Set the No.1 and No.5 journals of the camshaft on V-blocks.
2. Measure the camshaft runout using the dial
gauge.
• If it exceeds the maximum specification,
replace the camshaft.
bpe2ue00000031
01-10–30
1A36-1U-12L.book 31 ページ 2012年12月10日 月曜日 午前9時25分
MECHANICAL
4. Measure the journal diameter using the
micrometer. Measurement positions total four and
are in the X and Y directions, at two points (A and A B
B) as shown in the figure.
• If it is less than the minimum specification,
replace the camshaft.
X
Standard camshaft journal diameter 01-10
Y
24.96—24.98 mm {0.9827—0.9834 in}
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CYLINDER HEAD DISASSEMBLY (I).)
(6) Measure the camshaft journal oil clearance.
• If it exceeds the maximum specification,
replace the cylinder head.
End Of Sie
bp31je00000173
01-10–31
1A36-1U-12L.book 32 ページ 2012年12月10日 月曜日 午前9時25分
MECHANICAL
CYLINDER BLOCK INSPECTION
id011000507200
1. Measure the cylinder block for distortion in six
directions as shown in the figure using a straight
edge and feeler gauge.
• If it exceeds the maximum specification,
replace the cylinder block.
bp31je00000144
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89.000—89.030 mm {3.5040—3.5051 in}
PISTON INSPECTION
id011000502100
Caution
• If the piston is replaced, replace the piston, piston pin, and the snap ring as a single component.
01-10–32
1A36-1U-12L.book 33 ページ 2012年12月10日 月曜日 午前9時25分
MECHANICAL
3. Calculate the cylinder-to-piston clearance from the cylinder bore diameter and the piston outer diameter.
• If the clearance exceeds the maximum specification, replace the piston or cylinder block.
cardiagn.com
ring groove
Top: 0.12 mm {0.0047 in}
Second: 0.10 mm {0.0039 in}
Oil: 0.17 mm {0.0067 in}
End Of Sie
PISTON RING INSPECTION
id011000592300
1. Using the piston, press the piston ring parallel into
the cylinder to 43.9 mm {1.73 in} from the upper
PISTON
end of the cylinder block.
PISTON RING
bpe2ue00000094
End Of Sie
01-10–33
1A36-1U-12L.book 34 ページ 2012年12月10日 月曜日 午前9時25分
MECHANICAL
PISTON PIN INSPECTION
id011000507500
Caution
• If the piston or piston pin is replaced, replace the piston, piston pin and the snap ring as a single
component.
C
D
adj2224e255
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Standard piston pin hole diameter
21.004—21.008 mm {0.82693—0.82708 in} A
B
3. Calculate the clearance between the piston pin
hole diameter and the piston pin outer diameter.
C
• If it is not within the specification, replace the D Y
piston or the piston pin.
bpe1ze00000085
Standard clearance between connecting rod small end inner diameter and piston pin outer diameter
0.002—0.018 mm {0.00008—0.00070 in}
End Of Sie
01-10–34
1A36-1U-12L.book 35 ページ 2012年12月10日 月曜日 午前9時25分
MECHANICAL
PISTON AND CONNECTING ROD INSPECTION
id011000503100
1. Check the oscillation torque as shown in the
figure. Verify that the large end drops under its
own weight with no resistance.
• If the piston shakes heavily or unsmoothly,
disassemble the piston and connecting rod,
then inspect the following: (See 01-10-34
PISTON PIN INSPECTION.) 01-10
— Clearance between piston pin outer
diameter and piston pin hole diameter.
— Clearance between piston pin outer
diameter and connecting rod small end
inner diameter.
bp31je00000061
End Of Sie
CONNECTING ROD INSPECTION
id011000502800
1. Inspect the connecting rod for bending and
distortion using the connecting rod aligner.
• If it exceeds the maximum specification,
replace the connecting rod.
cardiagn.com
Maximum connecting rod distortion
0.050 mm {0.0020 in}
End Of Sie
CONNECTING ROD CLEARANCE INSPECTION
id011000507600
1. Measure the side clearance at the large end of
the connecting rod using a feeler gauge.
• If it exceeds the maximum specification,
replace the connecting rod or crankshaft.
01-10–35
1A36-1U-12L.book 36 ページ 2012年12月10日 月曜日 午前9時25分
MECHANICAL
Standard bearing oil clearance at the large end of the connecting rod
0.026—0.052 mm {0.0011—0.0020 in}
Maximum bearing oil clearance at the large end of the connecting rod
0.10 mm {0.0039 in}
End Of Sie
CRANKSHAFT INSPECTION
id011000502500
1. Measure the crankshaft end play using a dial
gauge.
• If it exceeds the maximum specification,
replace the crankshaft or grind the thrust side
of crankshaft and use the oversize thrust
bearing so that the specified end play is
obtained.
cardiagn.com
Maximum crankshaft end play
0.30 mm {0.012 in}
bpe2ue00000035
01-10–36
1A36-1U-12L.book 37 ページ 2012年12月10日 月曜日 午前9時25分
MECHANICAL
4. Inspect the main journal oil clearance using the following procedure:
(1) Install the thrust bearing, upper main bearing and crankshaft.
(2) Position a plastigauge on the journals.
(3) Install the lower main bearing and lower cylinder block. (See 01-10-40 CYLINDER BLOCK ASSEMBLY (I).)
(4) Remove the lower cylinder block. (See 01-10-22 CYLINDER BLOCK DISASSEMBLY (II).)
(5) Measure the main journal oil clearance.
• If it exceeds the maximum specification,
replace the main bearing, or grind the 01-10
main journal and use oversized bearings
so that the specified oil clearance is
obtained.
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End Of Sie
DUAL-MASS FLYWHEEL INSPECTION
id011000501900
Caution
• Do not rework the dual-mass flywheel if it is distorted.
• Do not clean the dual-mass flywheel with any kind of fluid. Clean the dual-mass flywheel with a dry
cloth only.
• Do not clean the gap between the primary and secondary mass. Only clean the bolt connection
surface and the clutch surface.
ac5wzw00005672
ac5wzw00005673
01-10–37
1A36-1U-12L.book 38 ページ 2012年12月10日 月曜日 午前9時25分
MECHANICAL
3. Measure the amount of guide pin projection of the
dual-mass flywheel.
• If it exceeds the maximum amount, replace
the dual-mass flywheel.
ac5wzw00005674
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ac5wzw00005675
Note
• Correct slight scratches and discoloration
using sandpaper.
ac5wzw00005676
ac5wzw00005677
01-10–38
1A36-1U-12L.book 39 ページ 2012年12月10日 月曜日 午前9時25分
MECHANICAL
PILOT BEARING INSPECTION
id011000505200
1. Without removing the pilot bearing, turn the
bearing while applying force in the axial direction.
• If there is any malfunction, replace the pilot
bearing.
End Of Sie
01-10
am3uuw00002078
BOLT INSPECTION
id011000503300
1. Measure the length of the each bolt.
• If it exceeds the maximum specification,
replace the bolt.
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Maximum cylinder head bolt length L
146.5 mm {5.768 in}
End Of Sie
01-10–39
1A36-1U-12L.book 40 ページ 2012年12月10日 月曜日 午前9時25分
MECHANICAL
CYLINDER BLOCK ASSEMBLY (I)
id011000504000
1. Assemble in the order indicated in the table.
15
OIL
13
1
OIL
10 12
R
2
12
R
8—11 N·m
{82—112 kgf·cm,
OIL
3 71—97 in·lbf}
OIL
11
9 18 R
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OIL
4
6 OIL
OIL
14
OIL
16 7 OIL
17
20—26
{2.1—2.6,
26—32 {2.7—3.2, 20—23}
15—19} 5 8
+80—100° SEALANT
bpe5ue00000004
01-10–40
1A36-1U-12L.book 41 ページ 2012年12月10日 月曜日 午前9時25分
MECHANICAL
13 Piston ring 16 Lower connecting rod bearing
(See 01-10-45 Piston Ring Assembly Note.) (See 01-10-46 Connecting Rod Bearing Assembly
14 Upper connecting rod bearing Note.)
(See 01-10-46 Connecting Rod Bearing Assembly 17 Connecting rod cap
Note.) (See 01-10-47 Connecting Rod Cap Assembly
15 Piston, connecting rod Note.)
(See 01-10-46 Piston, Connecting Rod Assembly 18 Pilot bearing (MTX)
Note.) (See 01-10-47 Pilot Bearing Assembly Note.) 01-10
Caution
• If the thrust bearings and main bearings are reused, assemble the bearings to the same positions
and in the direction as before removal to prevent engine damage due to seizure or burning of the
bearing.
• To prevent engine damage due to seizure or burning of the bearing, apply engine oil to the sliding
part when assembling.
Thrust bearing
1. Apply clean engine oil to the thrust bearings.
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2. Assemble the bearings with the oil groove of the THRUST BEARING
thrust bearing pointed toward the sliding surface.
OIL GROOVE
bpe1ze00000043
Main bearing
1. Apply clean engine oil to the main bearings.
2. Align the positioning tab of the main bearing with
MAIN BEARING GROOVE
the positioning groove of the lower and upper
cylinder block, and assemble the bearings. TAB
CYLINDER BLOCK
AFTER INSTALLATION
bpe1ze00000044
01-10–41
1A36-1U-12L.book 42 ページ 2012年12月10日 月曜日 午前9時25分
MECHANICAL
Plate Assembly Note
Caution
• Placing the crankshaft on a disassembly bench will deform or damage it because the plate for the
crankshaft position sensor signal detection installed to the crankshaft is larger than the
counterweight. Therefore, set wood blocks or similar objects on the both sides of the crankshaft
so that the plate does not contact the disassembly bench directly when placing the crankshaft on
it bench.
Tightening torque
20—26 N·m {2.1—2.6 kgf·m, 15—19 ft·lbf} C B
CRANKSHAFT
bpe2ue00000038
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Lower Cylinder Block Assembly Note
1. Completely clean and remove any oil, dirt, sealant or other foreign matter that may be adhering to the lower
cylinder block and cylinder block.
2. When reusing the lower cylinder block installation bolts, clean any old sealant from the bolts.
Caution
• Apply silicon sealant in a single, unbroken line.
• To prevent silicon sealant from hardening, adhere the engine front cover and the cylinder block
firmly within 10 min. after applying silicon sealant. After adhering them, tighten the installation
bolts immediately.
• Using bolts with the old seal adhering
could cause cracks in the cylinder block.
DAMAGE
OLD SEALANT
bpe2ue00000039
01-10–42
1A36-1U-12L.book 43 ページ 2012年12月10日 月曜日 午前9時25分
MECHANICAL
3. Apply silicon sealant to the lower cylinder block shown in the figure.
ENGINE FRONT
01-10
SEALANT
LESS THAN
4 mm {0.2 in}
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A
SEALANT LOWER CYLINDER
BLOCK LESS THAN
4 mm {0.2 in}
SECTION A-A
SEALANT
0.5—1.5 mm
{0.02—0.05 in}
SEALANT
bpe1ze00000046
Bead thickness
2—6 mm {0.1—0.2 in}
01-10–43
1A36-1U-12L.book 44 ページ 2012年12月10日 月曜日 午前9時25分
MECHANICAL
(2) Tighten lower cylinder block installation bolts A A A A A
A in the order shown in the figure using the
following procedure: 10 6 2 3 7
Tightening procedure
Step 1: 38—42 N·m {3.9—4.2 kgf·m, 29—30
ft·lbf}
Step 2: Loosen all the bolts (until bolts are
torque-free).
Step 3: 30—34 N·m {3.1—3.4 kgf·m, 23—25 ENGINE
ft·lbf} FRONT
Step 4: 57.5—62.5°
9 5 1 4 8
A A A A A
bpe2ue00000041
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6. After verifying that silicone sealant protrudes to
the rear oil seal press-in part, wipe away the
excess silicone sealant.
• If silicone sealant does not protrude to the ENGINE
rear oil seal press-in part, remove the lower FRONT
cylinder block and apply silicone sealant
again.
9 5 1 4 8
B B B B B
bpe2ue00000042
Note
• When assembling the piston to the connecting rod, each one can be assembled in either direction.
Caution
• Do not compress the outer diameter of the snap ring more than necessary when assembling the
snap ring (20.66 mm {0.8134 in} or less).
01-10–44
1A36-1U-12L.book 45 ページ 2012年12月10日 月曜日 午前9時25分
MECHANICAL
Piston Ring Assembly Note
Note
• It is not required to position the end gap between the top ring and second ring.
Note
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SECOND RING
END GAP
bpe1ze00000047
SECOND RING
NOTCH
bpe2ue00000044
01-10–45
1A36-1U-12L.book 46 ページ 2012年12月10日 月曜日 午前9時25分
MECHANICAL
Connecting Rod Bearing Assembly Note
Caution
• If a connecting rod bearing is reused, assemble it to the same position and in the direction as
before removal to prevent engine damage due to seizure or burning of the bearing.
• To prevent engine damage due to seizure or burning of the bearing, apply engine oil to the sliding
part when assembling.
CONNECTING ROD
BEARING CONNECTING ROD CAP
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INSTALLED
bpe1ze00000048
ENGINE
FRONT
6TN
G
2
MARKED
IN
bpe2ue00000045
01-10–46
1A36-1U-12L.book 47 ページ 2012年12月10日 月曜日 午前9時25分
MECHANICAL
Connecting Rod Cap Assembly Note
Caution
• When assembling the connecting rod caps, align the broken, rough faces of the connecting rods
and connecting rod caps.
• If the following condition is met, replace the connecting rod cap bolts.
— Length exceeds maximum
specification 01-10
Standard connecting rod cap bolt length
43.7—44.3 mm {1.73—1.74 in}
Tightening procedure
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Step 1: 26—32 N·m {2.7—3.2 kgf·m, 20—23 ft·lbf}
Step 2: 80—100°
Tool
Snap-on brand millimeter size bushing
driver set (A160M) adapter A160M7 (20—
22 mm {0.79—0.86 in})
• Use the adapter with the 20 mm {0.79 in}
side of the A160M7 (20—22 mm {0.79—
0.86 in}) facing the pilot bearing side.
Substitution tool
bpe2ue00000046
Outer diameter: 21 mm {0.83 in}
Inner diameter: 19 mm {0.75 in}
CRANKSHAFT A
bpe2ue00000047
01-10–47
1A36-1U-12L.book 48 ページ 2012年12月10日 月曜日 午前9時25分
MECHANICAL
CYLINDER BLOCK ASSEMBLY (II)
id011000504100
1. Assemble in the order indicated in the table.
R
OIL ATX
SST 7 8 108—116
5 6 {11.1—11.8,
80—85}
R SST
9
4 R
MTX 152—160
7 {15.5—16.3,
113—118}
R SST
11 9
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17—23
20—26 {2.1—2.6, 15—19} {1.8—2.3,
13—16}
R
1
10
*1
16—22 {1.7—2.2, 12—16}
+30—36 {3.1—3.6, 23—26}
*1
2
3
*1: 8—11 N·m {82—112 kgf·m, 71—97 ft·lbf} N·m {kgf·m, ft·lbf}
bpe5ue00000005
01-10–48
1A36-1U-12L.book 49 ページ 2012年12月10日 月曜日 午前9時25分
MECHANICAL
Balancer Unit Assembly Note
1. Assemble the balancer unit using the following procedure:
(1) Tighten the bolts in the order shown in the BALANCER UNIT
figure.
2 3
01-10
ENGINE
4 1 FRONT
bpe1ze00000051
Tightening torque
Installation position Tightening torque
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1—4 16—22 N·m {1.7—2.2 kgf·m, 12—16 ft·lbf}
5, 6 20—26 N·m {2.1—2.6 kgf·m, 15—19 ft·lbf}
ENGINE
4 1 FRONT
bpe1ze00000052
01-10–49
1A36-1U-12L.book 50 ページ 2012年12月10日 月曜日 午前9時25分
MECHANICAL
Oil Pump Assembly Note
1. Install the oil pump using the following procedure:
(1) Temporarily tighten the three bolts shown in
the figure.
BOLT
OIL PUMP
BOLT
BOLT
ENGINE FRONT
bpe1ze00000053
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Note
• The tightening order for the two bolts is
optional.
BOLT
Tightening torque
20—26 N·m {2.1—2.6 kgf·m, 15—19 ft·lbf} OIL PUMP
BOLT
ENGINE FRONT
bpe1ze00000054
Tightening torque
20—26 N·m {2.1—2.6 kgf·m, 15—19 ft·lbf}
OIL PUMP
BOLT
ENGINE FRONT
bpe1ze00000055
01-10–50
1A36-1U-12L.book 51 ページ 2012年12月10日 月曜日 午前9時25分
MECHANICAL
Water Pump Assembly Note
Caution
• Assemble the water pump gasket to the correct direction shown in the figure. Otherwise, it could
leak engine coolant and damage the engine.
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bpe2ue00000053
1. Insert a new water pump gasket into the water pump groove.
2. Install the water pump.
3. Tighten the bolts in the order shown in the figure.
Tightening torque
20—26 N·m {2.1—2.6 kgf·m, 15—19 ft·lbf}
WATER PUMP
1
3 2
bpe2ue00000054
01-10–51
1A36-1U-12L.book 52 ページ 2012年12月10日 月曜日 午前9時25分
MECHANICAL
Rear Oil Seal Assembly Note
1. Apply clean engine oil to the inner surface of a new rear oil seal.
2. Insert the rear oil seal into the cylinder block by hand.
3. Tap the oil seal in evenly using the SST and a
hammer.
49 S033 101 A
VIEW FROM A
CYLINDER BLOCK
HAMMER
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49 S033 101
bpe1ze00000056
SECTION B-B
CYLINDER BLOCK
0—0.5 mm
{0—0.019 in}
bpe5ue00000006
01-10–52
1A36-1U-12L.book 53 ページ 2012年12月10日 月曜日 午前9時25分
MECHANICAL
End Plate Assembly Note
1. After end plate assembly, crimp the parts A and B shown in the figure.
B
END PLATE
10 {0.39}
A
45°
45° 01-10
10 {0.39}
10 {0.39}
45° 45°
mm {in}
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bpe2ue00000055
Crimp procedure
Crimp depth: 0.1—1.0 mm {0.004—0.039 in}
Crimp width: 0.5—10.0 mm {0.02—0.39 in}
Crimp locations: Part A is 1 or more on one-side within shaded area and part B is 2 or more within
shaded areas
2. After crimping, verify that there is no damage and removal of the end plate.
Dual-mass Flywheel (MTX)/ Drive Plate (ATX) Installation Bolt Assembly Note
Dual-mass flywheel installation bolt (MTX)
1. Hold the crankshaft using the SST (49 E011 1A0).
2. Temporarily tighten the new bolts.
Note
• If the dual-mass flywheel (secondary flywheel side) is not positioned properly, perform the following
procedure to install it:
49 G033 102
49 E011 1A0
am6zzw00011777
01-10–53
1A36-1U-12L.book 54 ページ 2012年12月10日 月曜日 午前9時25分
MECHANICAL
(2) Install the SST (49 S120 710) to the dual-
49 E011 1A0
mass flywheel.
(3) Rotate the dual-mass flywheel (secondary
flywheel side) using the SST (49 S120 710),
and then temporarily tighten the remaining 49 G033 102
new bolt after removing the SST (49 G033
102).
49 S120 710
am6xuw00005541
Tightening torque 8
152—160 N·m {15.5—16.3 kgf·m, 113—118 1
ft·lbf} 6
3
5 4
49 E011 1A0 7 2
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ac5wzw00005664
Tightening torque
108—116 N·m {11.1—11.8 kgf·m, 80—85 1
ft·lbf} 3 6
5
4
2
49 E011 1A0
bpe1ze00000093
60º
KS
am6zzw00008568
01-10–54
1A36-1U-12L.book 55 ページ 2012年12月10日 月曜日 午前9時25分
MECHANICAL
CYLINDER HEAD ASSEMBLY (I)
id011000504300
1. Assemble in the order indicated in the table.
SST 6 7 8 9
5
4 01-10
SST R 2
1
8—11
{82—112,
71—97}
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OIL
3
N·m {kgf·cm, in·lbf}
bpe1ze00000017
01-10–55
1A36-1U-12L.book 56 ページ 2012年12月10日 月曜日 午前9時25分
MECHANICAL
Valve Seal Assembly Note
1. Press on the valve seal to the valve guide using
the SST by hand.
3.5 mm
{0.14 in}
VALVE SEAL
49 B012 016
VALVE SEAL
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bpe1ze00000057
Caution
• The valve springs differ depending on IN
and EX sides. Therefore, verify the free IN
48.96 mm {1.928 in}
length or identification paint beforehand
and assemble the valve springs correctly.
EX
50.07 mm {1.971 in}
NOT
PAINTE
bpe1ze00000094
01-10–56
1A36-1U-12L.book 57 ページ 2012年12月10日 月曜日 午前9時25分
MECHANICAL
Valve Keeper Assembly Note
1. Install the valve keeper using the SST.
49 0636 100B
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bpe1ze00000020
SECTION B-B
WATER OUTLET
GASKET
BEAD
bpe1ze00000021
01-10–57
1A36-1U-12L.book 58 ページ 2012年12月10日 月曜日 午前9時25分
MECHANICAL
3. Tighten bolt A of the 5 bolts shown in the figure to
BOLT
the specified torque first.
A
Tightening torque
8—11 N·m {82—112 kgf·cm, 71—97 in·lbf}
Note
• The tightening order for the remaining 3
bolts is optional.
A BOLT
bpe1ze00000022
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THERMOSTAT
bpe1ze00000023
01-10–58
1A36-1U-12L.book 59 ページ 2012年12月10日 月曜日 午前9時25分
MECHANICAL
CYLINDER HEAD ASSEMBLY (II)
id011000504400
Caution
• If the camshaft is rotated with the timing chain removed and the piston at the top dead center
position, the valve may contact the piston and the engine could be damaged. When rotating the
camshaft with the timing chain removed, rotate it after lowering the piston from the top dead
center position.
• When rotating the camshaft using a 01-10
WRENCH
wrench on the cast hexagon, the wrench CAMSHAFT
may contact the rocker arm and damage CAST HEXAGON
the rocker arm. To prevent damage to the
rocker arm when holding the camshaft on
the cast hexagon, use a wrench on the
rear side of the engine as shown in the
figure to secure a clearance between the
cam.
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DOES NOT CONTACT
am3uuw00008968
Note
• Width at the cast hexagon of the camshaft is CAMSHAFT
22—24 mm {0.87—0.94 in}.
CAST HEXAGON
22—24 mm
{0.87—0.94 in}
am3uuw00009029
01-10–59
1A36-1U-12L.book 60 ページ 2012年12月10日 月曜日 午前9時25分
MECHANICAL
1. Assemble in the order indicated in the table.
8—11 N·m 3.0—6.0 N·m
{82—112 kgf·cm, 8 {31—61 kgf·cm,
71—97 in·lbf} 27—53 in·lbf}
+8—11 N·m
9 {82—112 kgf·cm,
71—97 in·lbf}
7 OIL
10 4 OIL
12—16 N·m
R
{123—163 kgf·cm, OIL
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107—141 in·lbf}
WITHOUT OIL COOLER
13—17 N·m
{133—173 kgf·cm,
20—26
{2.1—2.6,
3 116—150 in·lbf}
+43—47
15—19}
{4.4—4.7, 32—34}
+85—95°
+85—95°
2
WATER
PUMP
01-10–60
1A36-1U-12L.book 61 ページ 2012年12月10日 月曜日 午前9時25分
MECHANICAL
Cylinder Head Assembly Note
Caution
• If the following condition is met, replace the cylinder head bolts.
— Length exceeds maximum
specification
Tightening procedure
Step 1: 13—17 N·m {133—173 kgf·cm, 116— 8
150 in·lbf}
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Step 2: 43—47 N·m {4.4—4.7 kgf·m, 32—34
ft·lbf} 7
Step 3: 85—95°
Step 4: 85—95° ENGINE
FRONT 3 2 6 10
am3uuw00008818
01-10–61
1A36-1U-12L.book 62 ページ 2012年12月10日 月曜日 午前9時25分
MECHANICAL
Water Inlet Pipe Assembly Note
Caution
• Do not apply oil (such as engine oil, ATF) to the O-ring of the water inlet pipe. Otherwise, the O-
ring could swell causing a seal malfunction.
1. Clean away the sealant adhering to the bolt hole on the cylinder block side of the water inlet pipe stay.
2. Apply engine coolant to the O-ring.
3. Install the O-ring to the water inlet pipe.
4. Insert the water inlet pipe into the water pump being careful not to damage the O-ring.
5. Install the water inlet pipe gasket with the gasket
projection facing the direction shown in the figure.
PROJECTION
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bpe2ue00000065
6. Tighten the bolts in the order shown in the figure. WATER OUTLET WATER INLET PIPE
1 20—26
12—16 N·m
{2.1—2.6,
{123—163 kgf·cm,
15—19}
107—141 in·lbf}
STAY
01-10–62
1A36-1U-12L.book 63 ページ 2012年12月10日 月曜日 午前9時25分
MECHANICAL
HLA Assembly Note
1. Perform HLA air bleeding using the following procedure:
(1) Put the HLA in a container filled with engine oil.
Caution
• Do not insert the round bar firmly because the check ball spring force is extremely weak.
1
ROUND BAR
PLUNGER
(APPROX. 1.0
2 mm {0.039 in}
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DIAMETER)
CHECK
BALL
bpe2ue00000067
HLA
VALVE
bpe2ue00000068
01-10–63
1A36-1U-12L.book 64 ページ 2012年12月10日 月曜日 午前9時25分
MECHANICAL
Camshaft Assembly Note
1. As shown in the figure, apply gear oil (SAE No. 90 or equivalent) or engine oil to the center area of each journal
of the cylinder head.
Caution
• Apply 0.05 ml {0.05 cc, 0.003 in3} or less of oil to journal No.6.
JOURNAL NO.6
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OIL
bpe2ue00000069
2. Apply gear oil (SAE No. 90 or equivalent) or engine oil to the following locations of each camshaft.
• Thrust surface of front journal
3. As shown in the figure, align the cam position of
cylinder No.1 around top dead center (TDC) and EXHAUST CAMSHAFT INTAKE CAMSHAFT
place the camshafts on the cylinder head.
CYLINDER HEAD
bpe2ue00000070
01-10–64
1A36-1U-12L.book 65 ページ 2012年12月10日 月曜日 午前9時25分
MECHANICAL
4. As shown in the figure, apply gear oil (SAE No. 90 or equivalent) or engine oil to the center area of each journal
of the camshaft.
01-10
OIL
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bpe1ze00000011
GROOVE ADHESIVE
bpe2ue00000071
01-10–65
1A36-1U-12L.book 66 ページ 2012年12月10日 月曜日 午前9時25分
MECHANICAL
7. Tighten the camshaft cap installation bolts in two steps in the order shown in the figure.
3 1 2 4 6
E2
E3
E4
E5
MARKED NUMBER
MARKED NUMBER
5
I2
I3
I4
I5
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4 2 1 3
am3uuw00008996
Tightening torque
Step 1: 3.0—6.0 N·m {31—61 kgf·cm, 27—53 in·lbf}
Step 2: 8—11 N·m {82—112 kgf·cm, 71—97 in·lbf}
Electric Variable Valve Timing Actuator, Hydraulic Variable Valve Timing Actuator Assembly Note
1. Align the knock pin on the end of the camshaft ELECTRIC VARIABLE VALVE
with the notch on the actuator (intake side) or TIMING ACTUATOR
knock pin installation hole (exhaust side), then
install the actuator to the camshaft.
INTAKE
CAMSHAFT
NOTCH KNOCK PIN
EXHAUST
CAMSHAFT
KNOCK PIN KNOCK PIN
INSTALLATION HOLE
bpe2ue00000072
01-10–66
1A36-1U-12L.book 67 ページ 2012年12月10日 月曜日 午前9時25分
MECHANICAL
2. Hold the camshaft using a wrench on the cast
hexagon, and tighten the actuator installation bolt.
Tightening torque
Electric variable valve timing actuator
(intake side): 102—114 N·m {10.5—11.6
kgf·m, 76—84 ft·lbf}
Hydraulic variable valve timing actuator 01-10
(exhaust side): 75—85 N·m {7.7—8.6 kgf·m,
56—62 ft·lbf}
Caution
• If the camshaft is rotated with the timing chain removed and the piston at the top dead center
position, the valve may contact the piston and the engine could be damaged. When rotating the
camshaft with the timing chain removed, rotate it after lowering the piston from the top dead
center position.
• When rotating the camshaft using a
WRENCH
wrench on the cast hexagon, the wrench CAMSHAFT
may contact the rocker arm and damage CAST HEXAGON
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the rocker arm. To prevent damage to the
rocker arm when holding the camshaft on
the cast hexagon, use a wrench on the
rear side of the engine as shown in the
figure to secure a clearance between the
cam.
Note
• Width at the cast hexagon of the camshaft is CAMSHAFT
22—24 mm {0.87—0.94 in}.
CAST HEXAGON
22—24 mm
{0.87—0.94 in}
am3uuw00009029
01-10–67
1A36-1U-12L.book 68 ページ 2012年12月10日 月曜日 午前9時25分
MECHANICAL
1. Assemble in the order indicated in the table.
4.5—7.0 N·m
A 24
{46—71 kgf·m,
40—61 ft·lbf}
23
SEALANT
R
14 8.0—9.0 N·m
R 9—12 N·m
{82—91 kgf·m,
71—79 ft·lbf}
{92—122 kgf·m,
80—106 ft·lbf}
16
22
20—26 A
{2.1—2.6,
15—19} R
*1 21 15—20
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{1.6—2.0,
12—14}
11
SEALANT
SEALANT
20
*1
R
19 18 17 OIL
SST
SST SEALANT
90—110
{9.2—11, 13
67—81}
+55—65°
*1
3
10 1
*1
2
8
12
9 7
SEALANT
15
20—30 4 6 5 *1
*1
{2.1—3.0,
15—22} SST SST
*1
38—46 {3.9—4.6, 29—33}
*1: 8—11 N·m {82—112 kgf·m, 71—97 ft·lbf} N·m {kgf·m, ft·lbf}
bpe1ze00000068
01-10–68
1A36-1U-12L.book 69 ページ 2012年12月10日 月曜日 午前9時25分
MECHANICAL
5 Oil pump chain 15 Oil pan
(See 01-10-69 Oil Pump Chain Assembly Note.) (See 01-10-77 Oil Pan Assembly Note.)
6 Balancer shaft sprocket 16 Electric variable valve timing motor/driver
(See 01-10-69 Oil Pump Chain Assembly Note.) (See 01-10-79 Electric Variable Valve Timing Motor/
7 Oil pump chain tensioner Driver Assembly Note.)
(See 01-10-69 Oil Pump Chain Assembly Note.) 17 Front oil seal
8 Crankshaft sprocket (See 01-10-80 Front Oil Seal Assembly Note.)
9 Chain guide (No.2) 18 Crankshaft pulley 01-10
10 Timing chain 19 Crankshaft pulley lock bolt
(See 01-10-71 Timing Chain Assembly Note.) (See 01-10-80 Crankshaft Pulley Lock Bolt Assembly
Note.)
11 Chain guide (No.1)
(See 01-10-71 Timing Chain Assembly Note.) 20 Water pump pulley
(See 01-10-81 Water Pump Pulley Assembly Note.)
12 Tensioner arm
(See 01-10-71 Timing Chain Assembly Note.) 21 Spark plug
13 Chain tensioner 22 Oil shower pipe
(See 01-10-71 Timing Chain Assembly Note.) (See 01-10-81 Oil Shower Pipe Assembly Note.)
14 Engine front cover 23 Cylinder head cover
(See 01-10-74 Engine Front Cover Assembly Note.) (See 01-10-82 Cylinder Head Cover Assembly Note.)
24 Dipstick
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1. Verify that the key and knock pin are aligned to
KEY
the positions shown in the figure.
• If they are not in the positions shown in the
figure, rotate the crankshaft and balancer
shaft (No.1) to set cylinder No.1 to top dead
center (TDC).
2. Temporarily assemble the oil pump driven
sprocket.
3. Temporarily tighten the oil pump driven sprocket
installation bolt.
BALANCER SHAFT
(NO.1) KNOCK PIN
bpe1ze00000070
bpe1ze00000071
01-10–69
1A36-1U-12L.book 70 ページ 2012年12月10日 月曜日 午前9時25分
MECHANICAL
5. Install the oil pump chain and balancer shaft sprocket as a single unit while aligning the alignment marks on
each sprocket and oil pump chain as shown in the figure.
BALANCER SHAFT
SPROCKET
ALIGNMENT MARK
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OIL PUMP CHAIN ALIGNMENT
MARK (ORANGE)
bpe1ze00000072
Caution
• At this stage, do not remove the wire or paper clip installed to the oil pump chain tensioner.
Tightening torque
20—30 N·m {2.1—3.0 kgf·m, 15—22 ft·lbf}
01-10–70
1A36-1U-12L.book 71 ページ 2012年12月10日 月曜日 午前9時25分
MECHANICAL
Timing Chain Assembly Note
1. Verify that the timing marks and the key are aligned to the position shown in the figure.
PIN
01-10
CYLINDER
HEAD
UPPER
SURFACE
TIMING MARK
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KEY
bpe5ue00000009
Note
• The timing mark of SKYACTIV-G 2.5 is not completely parallel with the upper surface of the cylinder head.
• If they are not in the position shown in the figure, rotate the camshaft and crankshaft to set the cylinder No.1
top dead center (TDC).
01-10–71
1A36-1U-12L.book 72 ページ 2012年12月10日 月曜日 午前9時25分
MECHANICAL
2. Install the timing chain while aligning the marks on each sprocket and the timing chain as shown in the figure.
TIMING CHAIN
ALIGNMENT MARK
(ORANGE)
PIN
CYLINDER
HEAD
UPPER
SURFACE
TIMING MARK
HYDRAULIC VARIABLE VALVE TIMING
ACTUATOR TIMING CHAIN ALIGNMENT MARK
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CRANKSHAFT SPROCKET
TIMING CHAIN TIMING CHAIN
ALIGNMENT MARK ALIGNMENT MARK
(YELLOW)
bpe1ze00000075
LINK PLATE
am3uuw00008861
01-10–72
1A36-1U-12L.book 73 ページ 2012年12月10日 月曜日 午前9時25分
MECHANICAL
8. Rotate the crankshaft clockwise two turns and inspect the valve timing.
PIN
CYLINDER
HEAD 01-10
UPPER
SURFACE
TIMING MARK
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KEY
bpe5ue00000010
Note
• The timing mark of SKYACTIV-G 2.5 is not completely parallel with the upper surface of the cylinder head.
01-10–73
1A36-1U-12L.book 74 ページ 2012年12月10日 月曜日 午前9時25分
MECHANICAL
Engine Front Cover Assembly Note
Note
• For a new engine front cover, the positioning
pins in the two locations shown in the figure
project to the outside of the engine.
VIEW FROM A
ENGINE OUTSIDE
POSITIONING
PIN
SEAL SIDE
POSITIONING PIN
A
bpe1ze00000006
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surface side.
2. Completely clean and remove any oil, dirt, sealant
or other foreign matter that may be adhering to
the engine front cover, cylinder head, and cylinder
block.
3. When reusing the engine front cover installation
bolts, clean any old sealant from the bolts.
Caution
• Apply the silicon sealant in a single,
unbroken line. ENGINE OUTSIDE
• To prevent silicone sealant from
hardening, adhere the engine front cover
to the cylinder block within 10 min. after 0—1 mm
{0—0.03 in}
silicone sealant is applied. Tighten the
installation bolts completely soon after
adhering.
POSITIONING
PIN SEAL SIDE
WOOD SLAB
POSITIONING PIN
bpe1ze00000007
DAMAGE
OLD SEALANT
bpe1ze00000008
01-10–74
1A36-1U-12L.book 75 ページ 2012年12月10日 月曜日 午前9時25分
MECHANICAL
4. Apply silicone sealant to the engine front cover as shown in the figure.
A
SEALANT
10 {0.39} 01-10
10 {0.39}
C
B
10 {0.39} B
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C
10 {0.39} B
A SECTION D-D
0.5—1.5 mm
{0.02—0.05 in}
SEALANT
B
90° 10 {0.39}
C
B
B ENGINE FRONT
32.5 {1.28}
C COVER
B 10 {0.39} 10 {0.39}
mm {in}
bpe1ze00000078
Bead thickness
A: 2—6 mm {0.1—0.2 in}
B: 4—6 mm {0.16—0.23 in}
C: 4—8 mm {0.2—0.3 in}
01-10–75
1A36-1U-12L.book 76 ページ 2012年12月10日 月曜日 午前9時25分
MECHANICAL
5. Apply silicone sealant to the areas shown in the
figure.
Caution
• Apply the silicone sealant so that it goes
into the cylinder head gasket. A
Note
• Temporarily install an appropriate bolt to the VIEW FROM A
drive belt auto tensioner installation bolt hole SEALANT
to prevent:
— A silicone sealant adhesion malfunction
in the drive belt auto tensioner
installation bolt hole.
— A bolt mis-installation due to silicone CYLINDER HEAD
sealant hardening. SEALANT
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am3uuw00008866
Caution
• For the number 10 bolt of the tightening
order, install the bolts with new washer.
am3uuw00008867
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1A36-1U-12L.book 77 ページ 2012年12月10日 月曜日 午前9時25分
MECHANICAL
8. Tighten the engine front cover installation bolts in the order shown in the figure.
15 19 16 20
01-10
1
11
12
7 8 R WASHER
4 5
3 2
10 9 M8 x 1.25, LENGTH
40 mm {1.6 in}
13
6 10
14 17
22 18 21
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bpe1ze00000079
Tightening torque
20—26 N·m {2.1—2.6 kgf·cm, 15—19 in·lbf}
9. Remove the bolt installed to the drive belt auto tensioner installation bolt hole when installing the drive belt auto
tensioner.
Caution
• Apply the silicon sealant in a single, unbroken line around the whole perimeter.
• To prevent silicone sealant from hardening, adhere the oil pan to the cylinder block within 10 min.
after silicone sealant is applied. Tighten the installation bolts completely soon after adhering.
• Using bolts with the old seal adhering
could cause cracks in the cylinder block.
DAMAGE
OLD SEALANT
am6zzw00002304
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MECHANICAL
3. Apply silicone sealant to the oil pan along the inside of the bolt holes as shown in the figure.
CYLINDER BLOCK
A SEALANT
SEALANT
OIL PAN
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bpe5ue00000011
Thickness
3.0—7.0 mm {0.12—0.27 in}
BOLT
BOLT
bpe1ze00000081
Tightening torque 17
10
8—11 N·m {82—112 kgf·cm, 71—97 in·lbf} 19 14
20 13
9
18
16 12 8 4 1 5
bpe1ze00000082
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1A36-1U-12L.book 79 ページ 2012年12月10日 月曜日 午前9時25分
MECHANICAL
Electric Variable Valve Timing Motor/Driver Assembly Note
1. Install a new O-ring to the O-ring installation groove of the engine front cover.
Caution
• To prevent damage to the electric
variable valve timing motor/driver, do not
apply excessive force (force of 100 N
{10.2 kgf, 22.5 lbf} or more) to the shaded 01-10
areas shown in the figure.
bpe1ze00000009
Note
• The eccentric shaft on the electric variable
valve timing actuator side can be rotated to
JOINT GROOVE
the left and right.
• The electric variable valve timing motor/
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driver can be assembled with the joint
groove of the eccentric shaft in any position, ECCENTRIC
and it will not lead to vehicle damage or SHAFT
performance reduction.
Tightening torque
20—26 N·m {2.1—2.6 kgf·m, 15—19 ft·lbf} ELECTRIC VARIABLE ELECTRIC VARIABLE
VALVE TIMING VALVE TIMING ACTUATOR
MOTOR/DRIVER
am3uuw00009043
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1A36-1U-12L.book 80 ページ 2012年12月10日 月曜日 午前9時25分
MECHANICAL
Front Oil Seal Assembly Note
1. Apply clean engine oil to the inner surface of a new front oil seal.
2. Insert the front oil seal into the engine front cover by hand.
3. Tap the oil seal in evenly using the SST and a
hammer.
49 G028 205 A
VIEW FROM A
ENGINE FRONT COVER
HAMMER
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49 G028 205
am3uuw00008830
B
SECTION B-B
ENGINE FRONT
COVER
0—0.5 mm
{0—0.019 in}
am3uuw00008831
Tightening procedure
Step 1: 90—110 N·m {9.2—11 kgf·m, 67—81
ft·lbf}
Step 2: 55—65°
49 E011 1A0
bpe1ze00000069
01-10–80
1A36-1U-12L.book 81 ページ 2012年12月10日 月曜日 午前9時25分
MECHANICAL
Water Pump Pulley Assembly Note
Caution
• Be careful not to damage the belt groove and surface of the water pump pulley when using tools,
otherwise it will cause wear, breakage, abnormal noise of the drive belt (stretch belt), damage to
the pulley, and rust.
1. Install the water pump pulley to the water pump and temporarily tighten the bolt. 01-10
2. Align the water pump pulley hole with the water
pump hole as shown in the figure.
WATER PUMP
HOLE HOLE
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bpe2ue00000081
Tightening torque
8—11 N·m {82—112 kgf·cm, 71—97 in·lbf}
BOLT
am3uuw00008874
OIL SHOWER
2 3 PIPE
am3zzw00012759
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1A36-1U-12L.book 82 ページ 2012年12月10日 月曜日 午前9時25分
MECHANICAL
Tightening torque
Installation position Tightening torque
1 9—12 N·m {92—122 kgf·cm, 80—106 in·lbf}
2, 3 8.0—9.0 N·m {82—91 kgf·cm, 71—79 in·lbf}
Caution
• To assure the sealing performance of the cylinder head cover, be careful of the following:
— Verify that the cylinder head cover gasket is inserted into the cylinder head cover groove and
install the cylinder head cover.
— Completely clean and remove any oil, dirt, sealant or other foreign matter from the seal
surface.
• To prevent silicone sealant from hardening, adhere the cylinder head cover and the cylinder head
within 10 min. after silicone sealant is applied. Tighten the installation bolts completely soon after
adhering.
1. Insert a new cylinder head cover gasket into the cylinder head cover groove.
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01-10–82
1A36-1U-12L.book 83 ページ 2012年12月10日 月曜日 午前9時25分
MECHANICAL
2. Apply silicone sealant to the areas shown in the figure.
ENGINE FRONT SIDE
SEALANT
CYLINDER HEAD
01-10
VIEW FROM A
2—6 mm 4—5 mm
3—13 mm 3—13 mm
{0.1—0.2 in} {0.16—0.19 in}
{0.2—0.5 in} {0.2—0.5 in}
SEALANT
ENGINE CYLINDER
FRONT HEAD
COVER
ENGINE FRONT
COVER MATCHING
2—6 mm 4—5 mm SURFACE
{0.1—0.2 in} {0.16—0.19 in}
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A
EXHAUST-SIDE REAR
CAMSHAFT CAP
VIEW FROM B
2—6 mm 2—6 mm
B
4—5 mm {0.1—0.2 in} {0.1—0.2 in}
SEALANT
{0.16—0.19 in}
EXHAUST-SIDE
REAR CAMSHAFT
CAP
2—6 mm
CYLINDER HEAD
{0.1—0.2 in}
CYLINDER HEAD
bpe2ue00000082
11
12
6 2 1 5
am3uuw00008879
01-10–83
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1A36-1U-12L.book 1 ページ 2012年12月10日 月曜日 午前9時25分
TECHNICAL DATA
01-50 TECHNICAL DATA
ENGINE TECHNICAL DATA . . . . . . . . . . 01-50–1
End of Toc
ENGINE TECHNICAL DATA
WM: ENGINE
id015000800100
01-50
Item Specification
OCV coil resistance 6.9—7.5 ohms [20°C {68°F}]
Maximum distortion, head gasket side of the cylinder
0.05 mm {0.002 in}
head
IN: 0.10 mm {0.0039 in}
Maximum distortion, manifold side
EX: 0.05 mm {0.002 in}
IN: Cutting not authorized
Maximum cutting length, manifold side
EX: 0.20 mm {0.0079 in}
Standard valve seat contact width 1.37—1.84 mm {0.0540—0.0724 in}
Valve seat angle 45°
IN: 48.93—50.17 mm {1.927—1.975 in}
Standard valve seat sinkage amount (Dimension L)
EX: 48.87—50.11 mm {1.925—1.972 in}
IN: 1.75—1.95 mm {0.0689—0.0767 in}
Standard valve head margin thickness
EX: 1.95—2.15 mm {0.0768—0.0846 in}
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IN: 107.00—107.60 mm {4.2127—4.2362 in}
Standard valve length
EX: 117.09—117.69 mm {4.6099—4.6334 in}
IN: 106.78 mm {4.2039 in}
Minimum valve length
EX: 116.87 mm {4.6012 in}.
IN: 5.470—5.485 mm {0.2154—0.2159 in}
Standard valve stem diameter
EX: 5.465—5.480 mm {0.2152—0.2157 in}
IN: 5.424 mm {0.2135 in}
Minimum valve stem diameter
EX: 5.419 mm {0.2133 in}
IN: 5.510—5.530 mm {0.2170—0.2177 in}
Standard valve guide inner diameter
EX: 5.510—5.530 mm {0.2170—0.2177 in}
IN: 0.025—0.060 mm {0.0010—0.0023 in}
Standard clearance between valve stem and guide
EX: 0.030—0.065 mm {0.0012—0.0025 in}
Maximum clearance between valve stem and guide 0.10 mm {0.0039 in}
IN: 16.4—17.0 mm {0.646—0.669 in}
Standard valve guide projection height
EX: 16.4—17.0 mm {0.646—0.669 in}
When pressurized with spring force of 228—252 N {23.3—25.6 kgf,
Valve spring installation height
51.3—56.6 lbf}, spring height is 38.0 mm {1.50 in}
IN: 2.0 ° (1.7 mm {0.067 in})
Maximum valve spring off-square
EX: 2.0 ° (1.7 mm {0.067 in})
Maximum camshaft runout 0.030 mm {0.0012 in}
IN: 42.34 mm {1.667 in}
Standard cam height
EX: 40.37 mm {1.589 in}
IN: 42.27 mm {1.664 in}
Minimum cam height
EX: 40.30 mm {1.587 in}
Standard camshaft journal diameter 24.96—24.98 mm {0.9827—0.9834 in}
Minimum camshaft journal diameter 24.93 mm {0.9815 in}
Standard camshaft journal oil clearance 0.035—0.080 mm {0.0014—0.0031 in}
Maximum camshaft journal oil clearance 0.090 mm {0.0035 in}
Standard camshaft end play 0.07—0.22 mm {0.003—0.008 in}
Maximum camshaft end play 0.23 mm {0.0091 in}
Maximum distortion, head gasket side of the cylinder
0.10 mm {0.0039 in}
block
Standard cylinder bore diameter 89.000—89.030 mm {3.5040—3.5051 in}
Oil jet valve opening pressure 180—220 kPa {1.84—2.24 kgf/cm2, 26.2—31.9 psi}
Standard piston outer diameter 88.965—88.995 mm {3.5026—3.5037 in}
Standard clearance between piston and cylinder 0.025—0.045 mm {0.0010—0.0017 in}
Maximum clearance between piston and cylinder 0.066 mm {0.0026 in}
01-50–1
1A36-1U-12L.book 2 ページ 2012年12月10日 月曜日 午前9時25分
TECHNICAL DATA
Item Specification
Top: 0.04—0.08 mm {0.002—0.003 in}
Standard clearance between piston ring and ring
Second: 0.03—0.07 mm {0.0012—0.0027 in}
groove
Oil: 0.04—0.12 mm {0.002—0.004 in}
Top: 0.12 mm {0.0047 in}
Maximum clearance between piston ring and ring
Second: 0.10 mm {0.0039 in}
groove
Oil: 0.17 mm {0.0067 in}
Top: 0.13—0.18 mm {0.0052—0.0070 in}
Standard piston ring end gap Second: 0.18—0.28 mm {0.008—0.011 in}
Oil (Rail): 0.10—0.35 mm {0.004—0.013 in}
Top: 0.35 mm {0.014 in}
Maximum piston ring end gap Second: 0.45 mm {0.018 in}
Oil (Rail): 0.52 mm {0.020 in}
Standard piston pin outer diameter 20.995—21.000 mm {0.82658—0.82677 in}
Standard piston pin hole diameter 21.004—21.008 mm {0.82693—0.82708 in}
Standard clearance between piston pin hole diameter
0.004—0.013 mm {0.0002—0.0005 in}
and piston pin outer diameter
Standard connecting rod small end inner diameter 21.002—21.013 mm {0.82686—0.82728 in}
Standard clearance between connecting rod small end
0.002—0.018 mm {0.00008—0.00070 in}
inner diameter and piston pin outer diameter
Maximum connecting rod bending 0.050 mm {0.0020 in}
Maximum connecting rod distortion 0.050 mm {0.0020 in}
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Connecting rod center-to-center distance 154.8 mm {6.094 in}
Standard side clearance at the large end of
0.14—0.36 mm {0.006—0.014 in}
connecting rod
Maximum side clearance at the large end of
0.465 mm {0.0183 in}
connecting rod
Standard bearing oil clearance at the large end of the
0.026—0.052 mm {0.0011—0.0020 in}
connecting rod
Maximum bearing oil clearance at the large end of the
0.10 mm {0.0039 in}
connecting rod
STD: 1.502—1.519 mm {0.05914—0.05980 in}
Connecting rod bearing size OS 0.25: 1.628—1.631 mm {0.06410—0.06421 in}
OS 0.50: 1.753—1.756 mm {0.06902—0.06913 in}
Standard crankshaft end play 0.08—0.29 mm {0.004—0.011 in}
Maximum crankshaft end play 0.30 mm {0.012 in}
STD: 2.500—2.550 mm {0.0985—0.1003 in}
Thrust bearing size
OS 0.25: 2.625—2.675 mm {0.1034—0.1053 in}
Maximum main journal runout 0.10 mm {0.0039 in}
Standard main journal diameter 49.980—50.000 mm {1.9678—1.9685 in}
Maximum main journal off-round 0.005 mm {0.0002 in}
Standard crank pin diameter 49.980—50.000 mm {1.9678—1.9685 in}
Maximum crank pin off-round 0.005 mm {0.0002 in}
Standard main journal oil clearance 0.016—0.039 mm {0.0007—0.0015 in}
Maximum main journal oil clearance 0.084 mm {0.0033 in}
STD: 2.489—2.510 mm {0.0980—0.0988 in}
Main bearing size OS 0.25: 2.614—2.617 mm {0.10292—0.10303 in}
OS 0.50: 2.739—2.742 mm {0.10784—0.10795 in}
Dual-mass flywheel guide pin projection maximum
11.0—12.0 mm {0.434—0.472 in}
amount
Dual-mass flywheel maximum runout 1.5 mm {0.059 in}
Standard cylinder head bolt length 145.2—145.8 mm {5.717—5.740 in}
Maximum cylinder head bolt length 146.5 mm {5.768 in}
Standard connecting rod bolt length 43.7—44.3 mm {1.73—1.74 in}
Maximum connecting rod bolt length 45.0 mm {1.77 in}
Rear oil seal press on amount 0—0.5 mm {0—0.019 in}
Front oil seal press on amount 0—0.5 mm {0—0.019 in}
End Of Sie
01-50–2
1A36-1U-12L.book 1 ページ 2012年12月10日 月曜日 午前9時25分
SERVICE TOOLS
01-60 SERVICE TOOLS
ENGINE SST . . . . . . . . . . . . . . . . . . . . . . 01-60–1
End of Toc
ENGINE SST
SOKYU_WM: ENGINE
id016000119200
1: Mazda SST number 01-60
2: Global SST number
Example
1: 49 E011 1A0
2: –
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1: 49 0636 1: 49 B012 1: 49 S120 170
100B 0A2A 2: –
2: – 2: –
Valve seal
Valve spring Pivot remover
lifter arm
1: 49 S120 710 1: 49 G033 102 1: 49 1285 071
2: – 2: – 2: –
1: 49 G028 205
2: –
— —
Oil seal installer
End Of Sie
01-60–1
1A36-1U-12L.book 2 ページ 2012年12月10日 月曜日 午前9時25分
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